Bicycle component and method for making such a component

Abstract

A pedal crank for a bicycle comprising structural fibers incorporated in a matrix of polymeric material which has two seats in which two metal inserts are received. The seats have a mouth which opens onto the outer surface of the pedal crank and have a geometry such as to allow the insertion of the inserts from outside of the pedal crank.

1. A force transmitting bicycle component comprising:
 a body of structural fibers incorporated in a matrix of polymeric material that has at least one seat with spaced apart ends that define a recess having a mouth at a first end, a base at a second end and a wall extending between the first and second ends that includes at least two body attachment zones; and 
 at least one metal insert that fits within the seat creating at least two insert attachment zones, one of said at least two insert attachment zones is dimensioned to complement one of the body's at least two attachment zones in an interference fit and a remaining one of said at least two insert attachment zones is dimensioned to define a gap between itself and a remaining one of said at least two body attachment zones, 
 wherein said at least one metal insert is configured to connect to a bottom bracket of a bicycle and has a widened head portion that abuts and extends beyond an outermost surface of said body. 
 
   
   
     2. The component of  claim 1  wherein the seat and the insert are mechanically coupled using coupling surfaces that are prism shaped. 
   
   
     3. The component of  claim 1  wherein the seat and the insert are mechanically coupled using coupling surfaces in the seat and the insert that are tapered. 
   
   
     4. The component of  claim 1  wherein the seat and the insert are mechanically coupled using coupling surfaces in the seat and the insert that are frusto-conical shaped. 
   
   
     5. The component of  claim 1  wherein the seat and the insert are mechanically coupled using coupling surfaces in the seat and the insert, the surfaces having one or more grooves. 
   
   
     6. The component of  claim 5  wherein the grooves extend longitudinally from the mouth to the base of the seat. 
   
   
     7. The component of  claim 1  wherein the at least two insert attachment zones have, in at least one portion thereof, an outer thread. 
   
   
     8. The component of  claim 1  wherein the seat and the metal insert are mechanically coupled using cylindrically shared coupling surfaces, and the coupling surface of the seat has, in at least one portion thereof, an inner threading defined on the base of the seat and the end part of the insert is also threaded. 
   
   
     9. The component of  claim 1  wherein the at least two insert and body attachment zones are threaded. 
   
   
     10. The component of  claim 1  wherein said one of said at least two insert attachment zones that forms said interference fit comprises one or more contact threads having a greater average, outer and core diameter with respect to threads of said one of said at least two insert attachment zones that forms said gap. 
   
   
     11. The component of  claim 1  wherein said one of said at least two insert attachment zones that forms said interference fit is placed near an end of said metal insert arranged at an opposite end of said metal insert from said one of said at least two insert attachment zones that forms said gap. 
   
   
     12. The component of  claim 1  wherein the seat and the metal insert are mechanically coupled using cylindrically shaped coupling surfaces on the seat and the insert, the coupling surface on the seat has, in at least one portion thereof, an inner threading defining a threaded hole that has a first coupling zone without clearance with the screw portion and a second coupling zone that has an interspace that is a gap between the insert and the threaded hole. 
   
   
     13. The component of  claim 12  wherein the first zone comprises one or more contact threads having an average, outer and core diameter smaller than the threads of the second zone. 
   
   
     14. The component of  claim 12  wherein the first zone is located nearer to the base than the mouth. 
   
   
     15. The component of  claim 1  wherein said base of said seat opens onto an outer surface of the body defining a through-hole configuration for said seat. 
   
   
     16. The component of  claim 1  wherein said base of said seat is confined to the inside of said body of the component. 
   
   
     17. The component of  claim 1  further comprising a removable covering element that covers the metal insert. 
   
   
     18. The component of  claim 1  wherein an adhesive contacts said seat and said metal insert. 
   
   
     19. The component of  claim 18  wherein the gluing substance consists of a bicomponent epoxy resin. 
   
   
     20. The component of  claim 18  wherein said walls of the seat and an outer surface of said metal insert define an interspace suitable for receiving said adhesive. 
   
   
     21. The component of  claim 20  wherein said interspace has a substantially uniform width. 
   
   
     22. The component of  claim 21  wherein said width of the interspace is between 0.1 and 0.05 mm. 
   
   
     23. The component of  claim 1  wherein the structural fibers are randomly arranged inside the matrix of polymeric material. 
   
   
     24. The component of  claim 1  wherein the structural fibers are arranged in an ordered manner inside the matrix of polymeric material. 
   
   
     25. The component of  claim 1  wherein the structural fibers are chosen from the group consisting of: carbon fibers, glass fibers, aramidic fibers, ceramic fibers or any combination thereof. 
   
   
     26. The component of  claim 1  wherein the metal insert comprises a light alloy. 
   
   
     27. The component of  claim 26  wherein the light alloy is aluminum. 
   
   
     28. The component of  claim 1  wherein the component is a pedal crank comprising:
 a second seat at an opposite end of the crank from said at least one seat where a second metal insert is received for connection to a bicycle pedal. 
 
   
   
     29. The component of  claim 28  wherein the at least one insert has a connection hole to the bottom bracket and the second insert has a connection hole to the pedal. 
   
   
     30. The component of  claim 28  wherein the pedal crank comprises a third seat and a third insert for the anchoring of a crown associated with the pedal crank. 
   
   
     31. The component of  claim 30  wherein the third insert is arranged in an intermediate position between the first insert and the second insert. 
   
   
     32. The component of  claim 28  wherein the pedal crank comprises one or more arms which extend radially with respect to the first seat and anchor a crown associated with the pedal crank. 
   
   
     33. The component of  claim 32  wherein the arms comprise seats and inserts for the anchoring of the crown. 
   
   
     34. A force transmitting bicycle component comprising:
 a body of structural fibers incorporated in a matrix of polymeric material that has at least one seat with spaced apart ends that define a recess having a mouth at a first end, a base at a second end and a wall extending between the first and second ends that includes at least two body attachment zones; and 
 at least one metal insert that fits within the seat creating at least two insert attachment zones, one of said at least two insert attachment zones is dimensioned to complement one of the body's at least two attachment zones in an interference fit and a remaining one of said at least two insert attachment zones is dimensioned to define a gap between itself and a remaining one of said at least two body attachment zones, 
 wherein said at least one metal insert is configured to connect to a bottom bracket of a bicycle, said base of said seat opens onto an outer surface of the body defining a through-hole configuration for said seat, and said metal insert has a widened head portion that abuts and extends axially outward from the outer surface of said body. 
 
   
   
     35. A bicycle crank comprising:
 an elongated body, formed of structural fibers incorporated in a matrix of polymeric material, having first and second ends and first and second sides; 
 at least one seat, defining an opening at one end of the body that extends between the sides and defines a mouth on one of the sides and a base on the other side, having walls that are substantially uniform between the mouth and the base; and 
 at least one metal insert comprising a first coupling zone that substantially engages one end of the opening and a second coupling zone defining an interspace that is a gap between the insert and the other end of the opening, 
 wherein said at least one metal insert has a widened head portion that abuts an outermost surface of said body, and extends axially outward from a plane formed by said outermost surface of said body. 
 
   
   
     36. A bicycle component comprising a body made from structural fibers incorporated in a matrix of polymeric material, the body comprising:
 at least one seat having an opening therein, the opening comprising: 
 a mouth at a first end of the opening; 
 a base at a second end of the opening opposite the first end being of a size not greater than the size of the mouth end; and 
 walls with cross-sections that do not increase from the mouth to the base; and 
 at least one metal insert that engages the seat; 
 wherein at least a portion of the metal insert extends axially outward from the body. 
 
   
   
     37. A force transmitting bicycle component comprising:
 a body of structural fibers incorporated in a matrix of polymeric material that has at least one seat with spaced apart ends that define a recess having a mouth at a first end, a base at a second end and a wall extending between the first and second ends that include at least two attachment portions; 
 at least one metal insert that fits within said seat and includes at least two attachment portions and a head portion, one of said at least two attachment portions is dimensioned to complement one of the body's attachment portions in an interference fit and a remaining one of said at least two attachment portions is dimensioned to define a gap between it and a remaining one of said at least two body attachment portions, the head portion configured to abut the body at a location radially outward of the mouth of the recess, and extend axially outward from an outermost surface of the body; and, 
 an adhesive within said gap between said respective body and insert attachment portions.